Der Respirationsfermentor – ein Labormeßsystem zur Charakterisierung aerober mikrobiologischer Reaktionen

By use of a laboratory fermenter with a gastight circle aeration system all interesting values connected with the respiration of microorganisms can be determined. The advantage of the respiration fermenter is the simple control of the oxygen partial pressure with high accuracy. The aeration is carried out by inert gas-oxygen-mixtures. This system was used to avoid errors in oxygen-concentration measurement and regulation by oxygen sensitive sensors in fermentation fluids. For each selected oxygen partial pressure in the course of fermentation the following date in connection with all desired analytical values can be determined by manual or automatical means. Total oxygen consumption, momentary oxygen consumption rate, kinetics of oxygen consumption rate, kinetics of respiratory quotient. Several opportunities of measurement are presented and examples for application in various microbial systems are given.     

Fluorimetrische und photometrische Schnellbestimmung von L-Lysin in Fermentationslösungen

In a methodical paper two analytical-chemical procedures are described which concern the control of L-lysine formation during fermentation processes. On one hand lysine is determined fluorimetrically with o-phthalaldehyde at defined pH, on the other spectrophotometrically with ninhydrine in acidic medium. The analytical conditions are discussed with respect to specifity, interferences, accuracy and reproducibility. A comparison of values with Autoanalyzer technique and two other methods for lysine determination offers the possibility to decide in what manner and with which aim of desired accuracy, economy and rapidity a given specimen has to be analyzed.     

Computer-aided material balancing for prediction of fermentation parameters.

Despite the importance of biomass as a parameter in fermentation processes, there are no commercially available sensors suitable for its measurement. An indirect approach for the assessment of biomass concentration can be based on material balances and on the direct monitoring of fermentation parameters for which there are established sensors (e.g., gaseous oxygen and carbon dioxide). As a consequence, this method requires no assumption of cellular yield coefficients or rate constants. This approach is also readily adaptable to general use since it requires only some knowledge of the compositions of the substrate, cells, and noncellular products.     

Prozeßtechnische Untersuchungen zur Ausschöpfung mikrobieller Leistungsgrenzen

The knowledge of the upper limits of growth rate and cell density is necessary to define the maximum possible productivity of a growth process. After a brief survey of the theoretical basis of microbial growth in dependence of mass transfer of oxygen and rheological properties of fermentation medium recent experimental results on the influence of higher pressure in the fermenter, of different substrate and dissolved oxygen concentrations on growth rate and yield coefficients of methanol utilizing bacteria are presented. Also some correlations between cell concentration and viscosity of fermentation broth are considered.     

Effects of microorganisms on effective oxygen diffusion coefficients and solubilities in fermentation media

Effective oxygen diffusion coefficients and solubilities were measured for submerged cultures of Saccharomyces cerevisiae, Escherichia coli, and Penicillium chrysogenum. Both effective oxygen diffusion coefficients and solubilities were found to decrease with increasing cell concentrations in the fermentation media. Comparison of the experimental results of effective oxygen diffusion coefficients in fermentation media with values theoretically predicted on the assumption of unpenetrable microbial cells indicates that oxygen molecules diffuse through the cells during the diffusion process. Within the cell concentration range of typical submerged fermentations, the effective oxygen diffusion coefficient of the fermentation media can be described as D(e) = A(1)f + A(2)f(2). In this equation, fis the cell volume fraction and both A(1) and A(2) are functions of the shape of the cells and the ratio of effective oxygen diffusion coefficient in microbial cells to that in the medium.     

Novel bioreactor internals for the cultivation of spore‐forming fungi in pellet form

This study introduced an automated long‐term fermentation process for fungals grown in pellet form. The goal was to reduce the overgrowth of bioreactor internals and sensors while better rheological properties in the fermentation broth, such as oxygen transfer and mixing time, can be achieved. Because this could not be accomplished with continuous culture and fed‐batch fermentation, repeated‐batch fermentation was implemented with the help of additional bioreactor internals (“sporulation supports”). This should capture some biomass during fermentation. After harvesting the suspended biomass, intermediate cleaning was performed using a cleaning device. The biomass retained on the sporulation support went through the sporulation phase. The spores were subsequently used as inocula for the next batch. The reason for this approach was that the retained pellets could otherwise cause problems (e.g., overgrowth on sensors) in subsequent batches because the fungus would then show undesirable hyphal growth. Various sporulation supports were tested for sufficient biomass fixation to start the next batch. A reproducible spore concentration within the range of the requirements could be achieved by adjusting the sporulation support (design and construction material), and an intermediate cleaning adapted to this.     

A Computer-aided noninterfering on-line technique for monitoring oxygen-transfer characteristics during fermentation processes

The role of computers in the monitoring and control of fermentation processes has increased steadfastly. The ultimate utility of the machines will not depend on the availability of online sensors but also on the availability of techniques that combine direct measurements, leading towards estimates of variable closely related to the microbial process or its control. In this article, a methodology for on-line and noninterfering evaluation of the volumetric mass-transfer coefficient K(l)a is developed. A detailed presentation of the procedure, called "the static method," is given. Its feasibility is proved through implementation of the method on an antibiotic fermentation process. These experiments indicate that operator actions meant to modify the oxygen-transfer conditions can be checked on-line. The quantitative value of the static method is ascertained by comparing the experimental results with K(l)a estimates obtained with the "gassing-out" method. A sensitivity analysis was carried out, revealing the need for temperature and pressure corrections and showing that the precision of the oxygen analyzer determines the precision of the static method.     

Rheologie von Fermentationslösungen

Rheological measurements can give interesting informations for the characterization of fermentation broth, especially concerning the depending of the oxygen transfer rate. Rheological measurements can report decisions for choosing the best reactor type or other process steps e.g. purification and separation. An advantageous method was used by the combination of a dynamic process-viscosimeter with the fermenter and the continuous measurement of medium density by X-ray absorption method.     

Prozeßsteuerung des O2-Partialdruckes der Kulturlösung bei aeroben mikrobiellen Fermentationen

Following the introduction referring to the fundamental role of the oxygen supply and the meaning of measured values of diluted oxygen in liquid culture media commonly used strategies to avoid the oxygen limitation in aerated fermentations are summarized and validated with respect to their realization requirements. Furthermore, a new developed principle for the control of the p O₂-value based on the growth regulating influence of the acidity (pH-value) without using the increase of the oxygen transport rate of the fermenter is discussed.     

On-line state estimation of biomass based on acid production in Zymomonas mobilis cultures

The concentrations of biomass, substrate and product are very important state variables of almost every bioprocess and generally unable to be measured directly in?situ due to the lack of reliable sensors. In this paper, an adaptive observer of the biomass concentration is proposed for an anaerobic fermentation process where only the measurement of the acid product is available on-line. The observer was tested to be effective by several experiments under various operating conditions. In this experimental system, an auto-sampling device was connected between the bioreactor for the fermentation of Zymomonas mobilis and a HPLC so that the concentrations of glucose and ethanol could be directly measured through such implementation.     

通过参数相关性分析对发酵控制策略在植酸酶高密度发酵中的作用探讨

为了优化植酸酶高密度发酵条件,有必要获取在发酵过程中由于控制策略引起有关参数的实时变化及其关联性.本研究利用传感器对植酸酶工程菌高密度发酵过程进行数据在线采集,通过改变转速、接种量与补料甘油,探讨三方面控制因素对高密度发酵产酶过程参数具体影响及各参数变化之间的相关性,建立起与转速-细胞密度-溶氧-乳酸相关的发酵罐内外环...     

Controlled supply of trace amounts of oxygen in laboratory scale fermentations

A detailed study of anaerobic yeast fermentations requires controlled addition of minor amounts of oxygen to the fermentor. A method for supplying small-scale fermentations with millimolar amounts of oxygen is described. The controlled addition is accomplished by diffusion of oxygen through silicone tubing carrying nitrogen to the fermentor. Sulfite values of the fermentation system are given for different gas velocities and lengths of silicone tubing. Two experiments are outlined in which this technique is applied and the possible energy yield from oxydative phosphorylation is discussed.     

Ein mikrorechnersystem für fermentationseinrichtungen

For several years now, we can notice efforts in increasing the efficiency of microbial processes by means of more intensive scientific investigation of such processes. Essential prerequisites to it are improved possibilities for process monitoring (available sensors) as well as facilities for realtime processing of process information. In this paper a microcomputer system is represented, which has been constructed on the base of computing needs for fermentation. The computing needs for fermentation experiments are outlined and the structure of the microcomputer is described. As an example it is illustrated what tasks can be solved by this microcomputer in coupled operation with a laboratory fermentor.     

Nonlinear estimation of specific growth rate for aerobic fermentation processes

The specific growth rate of the biomass, a very important parameter of almost every fermentation process, cannot be measured directly or estimated from related variables, as the concentrations of biomass, substrates, or products, due to the lack of reliable and cheap sensors. In this article a stable adaptive estimator of the specific growth rate is designed for those aerobic processes where the measurement of the oxygen uptake rate is available on-line. This particular approach can be applied also for other reaction rates if the model of the process satisfies some very general assumptions, which make the dynamics of the measured reaction rate a nonlinear function only of two unknown parameters, the specific growth rate and its time derivative. With respect to a previous similar approach, the new estimator has one additional parameter and a different nonlinear structure. From the analysis of the dynamics of the estimation error, a tuning criterion is derived, by which the two different algorithms can be compared under similar conditions. Simulation results show a good performance of both estimators for various kind of processes and disturbances. (c) 1995 John Wiley & Sons, Inc.     

A reassessment of mixing cost in fermentation processes

The gas–liquid oxygen transfer rate is a key step in the production of antibiotics in submerged fermentation. If the gas–liquid oxygen mass transfer rate is not equal to the required liquid–solid oxygen mass transfer rate at a particular cell concentration, then productivity of the particular fermentation operation will not be the maximum possible value. One way to increase the productivity of a given fermentation tank installation is to increase the cell concentration and to increase the oxygen transfer by changing the mixer and air supply to match the new requirements. In order to evaluate the cost of making this change to the larger mixing equipment, a typical cost example is given which can easily be modified for other combinations of production cost and mixer cost. As an example, it is seen that a considerable savings can result from a given installation by primarily changing the oxygen transfer ability of the equipment to utilize a given fermentor more efficiently. Production cost savings of 8 to 25% are shown in the example cited.     

Application of mass and energy balance regularities to product formation

Material and energy balances for fermentation processes with product formation are developed using regularities which are frequently useful in analyzing experimental results. Available electron balances are presented and used to analyze the results of experiments in which biomass and lysine are produced in batch culture using molasses and corn extract as organic substrates. Measured values of biomass productivity, lysine productivity, O₂ consumption rate, heat evolution rate, CO₂ evolution rate, and rate of utilization of reducing sugars (RS) are used to obtain estimates of biomass energetic yield, lysine energetic yield, and fraction of substrate energy evolved as heat. For two of the three experiments, based on the entire fermentation, the measured mass rate variables are very consistent and energy measurement errors are less than 10% when proper consideration is given to both the RS and the amino acids present in the organic substrate. The average measured value of 26.5 kcal/equivalent (equiv) of available electrons transferred to oxygen compares favorably with the known average value of 27 kcal/equiv.     

A shaken disposable bioreactor system for controlled insect cell cultivations at milliliter‐scale

While wave‐mixed and stirred bag bioreactors are common devices for rapid, safe insect cell culture‐based production at liter‐scale, orbitally shaken disposable flasks are mainly used for screening studies at milliliter‐scale. In contrast to the two aforementioned bag bioreactor types, which can be operated with standard or disposable sensors, shaker flasks have not been instrumented until recently. The combination of 250 mL disposable shake flasks with PreSens's Shake Flask Reader enables both pH and dissolved oxygen to be measured, as well as allowing characterization of oxygen mass transfer. Volumetric oxygen transfer coefficients (k_La‐values) for PreSens 250 mL disposable shake flasks, which were determined for the first time in insect cell culture medium at varying culture volumes and shaker frequencies, ranged between 4.4 and 37.9/h. Moreover, it was demonstrated that online monitoring of dissolved oxygen in shake flasks is relevant for limitation‐free growth of insect cells up to high cell densities in batch mode (1.6×10⁷ cells/mL) and for the efficient expression of an intracellular model protein.     

Redox potential control and applications in microaerobic and anaerobic fermentations

Many fermentation products are produced under microaerobic or anaerobic conditions, in which oxygen is undetectable by dissolved oxygen probe, presenting a challenge for process monitoring and control. Extracellular redox potentials that can be detected conveniently affect intracellular redox homeostasis and metabolism, and consequently control profiles of fermentation products, which provide an alternative for monitoring and control of these fermentation processes. This article reviews updated progress in the impact of redox potentials on gene expression, protein biosynthesis and metabolism as well as redox potential control strategies for more efficient production of fermentation products, taking ethanol fermentation by the yeast Saccharomyces under microaerobic conditions and butanol production by the bacterium Clostridium under anaerobic conditions as examples.     

Meßeinrichtung zur kontinuierlichen Bestimmung flüchtiger organischer Substanzen in wäßrigen Medien

After a short review over methods for continuous determination of alcohols (methanol or ethanol) in fermentation liquids the working principle of a measuring device is described. With this apparatus preferentially low concentrations in the ppm-range can be measured, but it is also suitable for higher concentrations without the necessity of sample dilution. Indication is linear over a wide range. Finally some experiences with the practical use of the instrument are given.     

On-line measurement of gas production rates

Gas evolution rates represent an important variable to track in biological and certain electrochemical processes. Accurate gas flow rate sensors exist for gas streams possessing a pressure head, such as when pressurized air or oxygen is delivered to a fermentation process. However, these devices impose pressure heads that can inhibit gas production and, therefore, yield false measurements. Examples of effected processes would include electrochemical production of a gas at the electrode (e.g., electrolysis) or anaerobic fermentation (e.g., anaerobic production of methane). In this work, we present an on-line gas measurement technique that measures on-line gas production from an anaerobic microbial process that is continuously fed simulated food waste over a 6-month period. Commentary is given on the sensor's accuracy and ease of use within the context of long-term operation, ability to measure both low and high gas production rates, as well as its potential for process control and system-health monitoring.